Decorative acoustical panel construction

ABSTRACT

A porous acoustical-type panel having improved appearance and decorative value comprising a laminated structure of a combination of a substantially rigid fibrous body bonded with a translucent resin and adhered thereto a facing mat impregnated with a translucent resin and coloring pigment.

United States Patent inventors Theodore Richard Rohweder Toledo; GeorgeJ. Hannes, Maumee, Ohio Appl. No. 41,732 Filed June 1, 1970 PatentedJune 8, 1971 Assignee Johns-Manville Corporation New York, N.Y.

Continuation of application Ser. No. 779,748, Nov. 29, 1968, nowabandoned.

DECORATIVE ACOUSTICAL PANEL References Cited UNITED STATES PATENTS DiMaio et a1 Keller et a1.

Capaul l-lannes et a1... 6/1967 Johnston 12/1968 Jackson FOREIGN PATENTS1/1957 France Primary ExaminerRobert S. Ward, Jr. Attorneys-John A.McKinney and Robert M. Krone 18l/33.1 181/33.1 181/33.l 161/157X181/33.l 181/33.1 181/33.1 l81/33.1 181/33.1 181/33.1

ABSTRACT: A porous acoustical-type panel having improved appearance anddecorative value comprising a laminated structure of a combination of asubstantially rigid fibrous body bonded with a translucent resin andadhered thereto a facing mat impregnated with a translucent resin andcoloring pigment.

DECORATIVE ACOUSTICAL PANEL CONSTRUCTION This application is acontinuation of copending application Ser. No. 779,748, which was filedNov. 29, 1968 and which is now abandoned.

BACKGROUND OF THE INVENTION Acoustical products such as ceiling or walltiles and panels etc., must, for effective sound dampeningtheir primefunction-be of a highly porous or open structure and in particular intheir exposed functional surface. This essential open or discontinuoussurface and porous structure of acoustical materials presents asignificant obstacle in enhancing ap pearance or producing decorativeeffects, as for example the application of paint films, in products suchas typical acoustical ceiling tiles. For instance, paint in sufficientamount to effectively hide the underlying surface and thus decorate theproduct significantly reduces the openings of the surface therebyblocking off the internal porous structure from its effectivesound-reducing function. In addition to the old means of coloring theentire or a substantial portion of the material throughout itscomposition, a technique which although normally very effective indecorative aspects is unduly expensive, because of the usually high costof pigments and amounts required, numerous other schemes have beenproposed to improve the appearance of open-faced and porous acousticalproducts including for example surfacing with perforated metal orplastic sheets or of other materials, covering with plastic films eitherimperforate or perforated, etc. However, these means'inevitably diminishthe sound dampening qualities of the product and frequently detract fromappearance and are often costly to manufacture or in materials.

SUMMARY OF THE INVENTION This invention comprises a unique laminatedstructure and composition amenable to the manufacture ofconventionaltype fibrous acoustical panels, such as common resin-bondedglass and/or other mineral fiber acoustical ceiling tile, etc., which byitself provides a decorative facing surface, or one which may beeffectively decorated as by the application of paint in such amounts asto retain the porous and open surface essential to sound abatement whileproviding an appealing, highly uniform appearance.

The laminated structure and composition of the invention essentiallyincludes a facing mat of open construction impregnated with atranslucent resin binder and coloring pigment which is applied over themajor and functional surface of the substantially rigid body of mineralfibers which may be of conventional structure and composition except forincluding a translucent thennosetting resin as the binder.

It is the primary object and advantage of this invention to provide anacoustical product having integral therewith a highly porous and opensurface of good appearance itself and of effective sound dampeningproperties, which surface additionally is amenable to painting ifdesired to enhance or revitalize the decorative effect withouteffectively diminishing the porosity and acoustical values attributablethereto, and also enables the easy application of paint to contribute toor modify the decorative appearance of acoustical tiles and panels whichis especially applicable to deeply concave domed or vaultedthreedimensional-type panels with steeply sloping sides.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a perspective view of a typicalhigh-vaulted threedimensional-type acoustical tile product with a cutoutsection illustrating the construction of this invention; and,

FIG. 2 is an exaggerated sectional view of the construction of theproduct illustrated in FIG. 1 taken along lines 2-2.

DESCRIPTION OF THE PREFERRED EMBODIMENT The decorative and porous sounddampening acoustical panel products of this invention essentiallycomprise a twocomponent laminated structure of a substantially rigid orselfsupporting body of generally random felted mineral fibers bondedwith a translucent resin, and having adhered to the major functionalsurface thereof which is to be decorated, a facing mat of mineralfilaments lying generally transverse to each other and impregnated witha combination of translucent resin and particulate pigments of the colordesired. This combination of the translucent resin bonded rigid mineralfiber body and facing thereon of open mat containing translucent resinbinder and pigment produces a composite structure which is both highlyporous and open in the exposed functional surfaces and continuing atleast partly through the body thereof, and yet presents a pleasing colordecorated surface finish, thereby rendering it well suitable for themanufacture of acoustical tiles and panels for ceiling, walls,partitions, and the like covering finishes. Moreover, when desired orfitting to paint the surface of the product, either initially inconjunction with manufacture, or subsequently to restore or changeappearance, the exposed functional surface is more amenable to paintingin that a decorative and effective hiding application with paint can beachieved with minimal amounts without closing or blocking the open andporous surface, thus maintaining acoustical values.

The substantially rigid or self-supporting body portion in the laminatedstructure of this invention comprises common mineral fibers, inparticular including fibers composed basically of siliceous or silicatecompositions such as typical glass fibers, or the wools or fibersderived from rock or other siliceous and argillaceous material, ormetallurgical slags which are well known in the industry and have longheretofore been employed in acoustical panel or tile products. Fiberscan be produced and collected in accordance with the commonmanufacturing procedures for glass fibers and related mineralcompositions, for example, as illustrated in U.S. Pat. Nos. 2,663,906,2,814,657, and 2,863,176, each to Labino, wherein the formed finediameter fibers (about 1 to 5 microns) are collected from theirdispersed state within a gassuspending medium in a generally random orhaphazardly arranged felted mass, including appropriate resin binderwhich is normally and preferably applied to the fiber while suspendedsubstantially individually in the gas medium prior to their collection.The thermosetting resin binder for the purpose of this invention shouldconsist of one which is translucent upon curing, such as melamineformaldehyde, ureaformaldehyde, polyester, and the like colorless ortranslucent synthetic materials.

However, to reduce cost, the generally rigid or self-supporting bodycomponent may be formed of two or more sections with only that sectionof the total body providing the outer functional surface to be facedwith the mat, being necessarily bonded with the translucent resinwhereby the back section or sections can employ substantially anythermosetting resin as a binder regardless of its color.

The facing mat consists of a scrim-type fabric either woven or nonwovenintercrossed strands of a highly open construction, and particularlymats of mineral filaments lying transverse to each other comprising themultilayered intercrossed filament product formed according to theprocesses and/or means of U.S. Pat. No. 2,574,22l, 2,609,320, 2,729,582,2,913,037, and 2,964,439, each to Modigliani, and Nos. 2,996,102, and3,220,811 to Schuller. Continuous glass or other mineral filamentsconstitute the optimum material, but twisted textile strands of staplemineral fibers generally may serve.

The facing mat is impregnated with a combination comprising an admixtureof translucent thermosetting resin and pigment, with the resin, as inthe case of at least the adjoining section of the rigid orself-supporting felted fiber body, being of a translucent material suchas melamine formaldehyde, ureaformaldehyde, or polyester resin. Panelsfor ceiling tile being generally white or off white, the pigment shouldbe white comprising for example, titanium dioxide, zinc oxide, whitelead, or a white clay and preferably titanium dioxide because of itssubstantially greater hiding capacity and absence of toxicity.Nevertheless, a colored pigment can be utilized to achieve a particularcolor but such use is restrictive insofar as the advantageous colorversatility of the product. Moreover, a flat white background such asprovided with these pigments presents an optimum surface for theapplication of very light pastel paints of any color as well as whitepaint, comprising the most appropriate color schemes for ceilings andpermits the application of such light-toned paint in rather thin andsubstantially discontinuous coatings which do not obstruct the porousstructure of the facing mat but aptly transmit the color effect. Aptproportions of resin to pigment comprise approximately 30 to 100 percentby weight of resin to approximately to 70 percent by weight of pigment,and preferably of ratios of about 30 to 50 percent by weight of resin toabout 50 to 70 percent by weight of pigment, but, of course, dependingupon the density of given pigments, the ratios can be varied. Theinclusion of pigment is not entirely essential, particularly when theproduct is to be painted.

Referring to the drawings, numeral designates a ceiling acoustical tileproduct of the common three-dimensional and high-domed or vaultedconstruction comprising a generally rigid body section 11 composed of amat of felted glass fibers bonded with melamine formaldehyde resin whichis translucent upon curing. Facing mat 12 is superimposed over thefunctional or front major surface of fiber body 11 of tile 10 andadhered thereto during manufacturing by means of the melamine resinbinder content of the body section 11 and of the facing mat itself. Mat12 contains a mixture of translucent melamine formaldehyde resin andtitanium dioxide white pigment which provides a flat white and poroussurface having good acoustical properties and which provides a pleasinguniform white appearance itself without the application of paint. Theconstruction of the invention is thus especially advantageous in themanufacture of high domed or vaulted three-dimensional panels havingsteeply sloped side portions such as in the product illustrated becausedue to the deep concave configuration and the steeply sloped sides ofthe product it is especially advantageous in the manufacture of highdomed or vaulted three-dimensional panels having steeply sloped sideportions such as in the product illustrated because due to the deepconcave configuration and the steeply sloped.

sides of the product it is especially difficult to apply paint uniformlyover the article with usual factory equipment and methods and achieve aconsistent overall color tone.

A typical product of this invention for use as an acoustical ceilingtile can be produced by means of the following exemplary procedure. Aloose felt or mass of. glass fiber of a thickness of about 1' inch and adensity of about 1.5 pounds per cubic foot of a type commonly used inthermal insulations and related products, containing substantiallyuniformly distributed throughout about 15 percent by weight thereof of Bstage melamine formaldehyde resin, is placed in a press mold with dyesof appropriate configuration design. Superimposed thereon is a facingmat of continuous glass filaments consisting of a plurality of layersoriented to lie generally transverse to each other as provided by theprocedure of the aforesaid patents to Modigliani or Schuller, weighingapproximately 2.5 grams per square foot and containing therethroughabout 2.0 grams per square foot of a mixture 60 percent by weighttitanium dioxide and 40 percent by weight of melamine formaldehyde resinin the "B" stage. The mold is closed upon the composite body of randomfibers and facing mat of intercrossed filaments and the said contentscompressed and subject to a temperature of about 420 F. for 40 seconds,whereupon the melamine formaldehyde resin content of the fibrous bodyand the facing mat is substantially cured, bonding the fibers of theloose felt to a rigid body of about 1 1.0 pcf, and securing the titaniumdioxide pigment within and about the facing mat while at the same timeadhering the facing mat to the rigid body forming a composite laminateof sufficient structural integrity to be substantially self-supporting.

The resulting formedand cured panel product exhibited a uniformly whitesurface for exposure having a flat or mat surface of good appearance.The product is decorative and useful without painting or other surfacetreatment. However, upon the spray application of white or light pastelcolor paint by means of a usual factory reciprocating spray gun,coverage is entirely adequate including the steep side slopes of deeplyconcave or vaulted three-dimensional tile. The openness of the facingmat causes the paint film to open up into many small pores producing adiscontinuous coating effectively preserving the good acousticalproperties attributable to the original unpainted product and yetexhibiting a good appearance of uniform coloring.

We claim:

1. A decorative, porous vaulted panel having sound dampening acousticalproperties consisting essentially of a composite laminated structure ofdeep concave configuration composed of a substantially rigidself-supporting body of generally random felted mineral fiber bondedwith at least one thermosetting translucent resin selected from thegroup consisting of melamine formaldehyde, ureaformaldehyde andpolyester, and having a facing mat superimposed conterminously with onemajor surface of the said substantially rigid self-supporting body offelted fiber and adhered thereto, said facing mat being composed ofmineral filaments lying generally transverse to each other andimpregnated with at least one thermosetting translucent resin selectedfrom the group consisting of melamine formaldehyde, ureaformaldehyde andpolyester.

2. The porous acoustical vaulted panel product of claim 1, wherein thefacing mat superimposed conterminously with and adhered to the saidrigid body of felted mineral fibers is impregnated with a combination oftranslucent resin and pigment in a ratio of about 30 to percent byweight of resin to about 0 to 70 percent by weight of pigment.

3. The porous acoustical vaulted panel product of claim 2, wherein thesaid impregnating composition of the facing mat comprises approximately30 to 50 percent by weight of resin and approximately 0 to 70 percent byweight of pigments.

4. The porous acoustical vaulted panel product of claim 2, wherein thepigment comprises at least one white pigment selected from the groupconsisting of titanium dioxide, zinc oxide, white lead, and clay.

5. The porous acoustical vaulted panel product of claim 4, wherein thethermosetting resin bond for the substantially rigid body of generallyrandom felted mineral fiber is melamine formaldehyde resin.

6. The porous acoustical vaulted panel product of claim 5, wherein thethermosetting resin of the impregnate for the facing mat of mineralfilaments lying generally transverse to each other is melamineformaldehyde resin.

7. The porous acoustical vaulted panel product of claim 6, wherein thewhite pigment is titanium dioxide.

8. The porous acoustical vaulted panel product of claim 7, wherein theimpregnating combination for the facing mat comprises approximately 40percent by weight of the resin and approximately 60 percent by weight ofthe white pigment.

9. The porous acoustical vaulted panel product of claim 8, having aporous coating of paint on the exposed surface of the facing mat.

10. The porous acoustical vaulted panel product of claim 9, wherein thefacing mat of mineral filaments lying generally transverse to each otherin a nonwoven fabric.

11. The porous acoustical vaulted panel product of claim 10, wherein thenonwoven fabric facing mat of mineral filaments lying generallytransverse to each other is an open scrim having a weight ofapproximately 2 to 3 grams per square foot.

12. The porous acoustical vaulted panel product of claim 1, wherein thesubstantially rigid body of generally random felted mineral fiber bondedwith thermosetting resin is composed of a plurality of sections with atleast the section adjacent to the facing mat being bonded with athermosetting translucent resin.

1. A decorative, porous vaulted panel having sound dampening acousticalproperties consisting essentially of a composite laminated structure ofdeep concave configuration composed of a substantially rigidself-supporting body of generally random felted mineral fiber bondedwith at least one thermosetting translucent resin selected from thegroup consisting of melamine formaldehyde, ureaformaldehyde andpolyester, and having a facing mat superimposed conterminously with onemajor surface of the said substantially rigid self-supporting body offelted fiber and adhered thereto, said facing mat being composed ofmineral filaments lying generally transverse to each other andimpregnated with at least one thermosetting translucent resin selectedfrom the group consisting of melamine formaldehyde, ureaformaldehyde andpolyester.
 2. The porous acoustical vaulted panel product of claim 1,wherein the facing mat superimposed conterminously with and adhered tothe said rigid body of felted mineral fibers is impregnated with acombination of translucent resin and pigment in a ratio of about 30 to100 percent by weight of resin to about 0 to 70 percent by weight ofpigment.
 3. The porous acoustical vaulted panel product of claim 2,wherein the said impregnating composition of the facing mat comprisesapproximately 30 to 50 percent by weight of resin and approximately 0 to70 percent by weight of pigments.
 4. The porous acoustical vAulted panelproduct of claim 2, wherein the pigment comprises at least one whitepigment selected from the group consisting of titanium dioxide, zincoxide, white lead, and clay.
 5. The porous acoustical vaulted panelproduct of claim 4, wherein the thermosetting resin bond for thesubstantially rigid body of generally random felted mineral fiber ismelamine formaldehyde resin.
 6. The porous acoustical vaulted panelproduct of claim 5, wherein the thermosetting resin of the impregnatefor the facing mat of mineral filaments lying generally transverse toeach other is melamine formaldehyde resin.
 7. The porous acousticalvaulted panel product of claim 6, wherein the white pigment is titaniumdioxide.
 8. The porous acoustical vaulted panel product of claim 7,wherein the impregnating combination for the facing mat comprisesapproximately 40 percent by weight of the resin and approximately 60percent by weight of the white pigment.
 9. The porous acoustical vaultedpanel product of claim 8, having a porous coating of paint on theexposed surface of the facing mat.
 10. The porous acoustical vaultedpanel product of claim 9, wherein the facing mat of mineral filamentslying generally transverse to each other in a nonwoven fabric.
 11. Theporous acoustical vaulted panel product of claim 10, wherein thenonwoven fabric facing mat of mineral filaments lying generallytransverse to each other is an open scrim having a weight ofapproximately 2 to 3 grams per square foot.
 12. The porous acousticalvaulted panel product of claim 1, wherein the substantially rigid bodyof generally random felted mineral fiber bonded with thermosetting resinis composed of a plurality of sections with at least the sectionadjacent to the facing mat being bonded with a thermosetting translucentresin.